Switch



July 23, 1940. R Popp 'E1- AL 2,209,104

swITcH Filed April 24, 1957 2 Sheets-Sheet l l J7 4 9 @l Z f@ J] A 5g 57 July 23, 1940. R. PoPP Er A1. 2,209,104

" SWITCH Filed April 24, 1937 sheets-sheet 2 LF l@ S ).2

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Patented July 23, 1940 PATENT orrlce 2,209,104 VSVVI'lOl-I Rudoli| Popp and Marvin C. Carlson, Valparaiso,

Ind., assignors to McGill Manufacturing Com- Dany, Indiana Valparaiso, Ind.,

a corporation of Application April 24, 1937, Serial No. 138,832

6 Claims.

Our invention relates in general to electric switches, and more in particular to a switch housing, which is particularly, but not solely adapted to house a multi-circuit control, doublepole switch for mounting in any position and adapted for remote control. The switching mechanism includes a plurality of superimposed circuit making and breaking elements,l and is pref.

erably encased in a snap cover housing accommodating this switch as well as the wires to the terminal members corresponding to the plurality of superimposed circuit making and breaking elements. The terminal members and associated contacts are assembled together by eyelets which automatically bind the elements of the assembly tightly together in the normal operation of mounting a wire conductor on the terminal member.

There has always been the problem in the control of a multiple circuit, particularly one carrying a heavy load, of making and breaking the circuit by the control switch therefor in such a manner that dangerous arcing is prevented. The possible arc is so great in the switch in a line carrying a heavy current, that unless this arc is properly dissipated, it will freeze the switching mechanism and burn up the switch, as well as cause damage in the electric circuit, and of course there is always the danger of iire to the material oi the house or building around the switch. As a result of this danger, the underwriters require that a double pole rather than a single pole switch be used in all heavy duty lines. This requirement is satisfied without a great deal of additional cost in the ordinary knife switch, but to get a similar effect in the rotary switching mechanism it has been necessary, up until the introduction of the multi-deck switch of the copending application, now issued as Patent No. 2,158,084, dated May 16, 1939, to applicant Popp, to use a very complicated, expensive, and cumbersome switch. The switch has been of such construction and size that there have been serious limitations with respect to mounting and assembling the switch for use with a multiple circuit, as well as a single circuit requiring a double-pole switch. The load in such circuits, as a motor, lamp, or the like, is often' mounted or assembled in relatively inaccessible places, at such an angle or in such a position that remote control on a switch therefor, in any position of such switch, is extremely desirable.

A particular application of this problem is presented in a circuit for controlling a two-filament lamp having an inert gas. A tremendous load is built up immediately upon making contact in the circuit with this load running often over 8D amperes, and after the circuit is made, tapering oi gradually to a normal load of ten amperes. Except for a switch of the construction of the above noted Popp patent, prior switches for controlling or operating such a lamp have been large, cumbersome and expensive. The commercial embodiment of the present invention is only 11/2 inches in diameter over the frame plates and 11/10 inch high, and in providing such a relatively small switch for a multiple circuit, high amperage line it was desirable to utilize a snap cover housing of the general type of that in the Despard -Patent No. 1,538,274. There was the problem in such a housing of,Il providing means for accommodating the closely ,spaced conductor wires going to the superimposed terminal plates so that such conductor wires could be iirst assembled on the switching mechanism, then such mechanism dropped into the housing with the conductors extending out of the housing to the circuit connections, but without any unnecessary waste space in the housing, nor any possibility of the closely spaced conductors becoming shorted.

In addition, there is a further problem in such a high capacity switch with the terminal structure made up of several elements secured together oforiginally providing, and subsequently maintaining a tight, clean contact between the elements of the terminal structure. This problem is particularly pressing in view of the fact that any insulating members in the post assembly will ordinarily shrink with age.

It is an object of the present invention to provide an improved simplified switch housing which offers a satisfactory solution to many rof these problems noted above of operation, assembly of they switch itself, and the mounting of the completed switch.

A further object oi my invention is the provision of improved switch housing structure which not only encloses the switch mechanism itself, but acts to insulatingly separate, and retain in relatively fixed positions, the conductors connected to the switch mechanism and extending out of the housing.

One'of the features oi the invention is the provision of a cup-shaped housing with a snap f cover particularly adapted for a multi-deck circuit control switch with the circuit conductors therefor extending to terminal plates spaced closely together and one above the other on a single post within the frame of the switching mechanism. The posts for the terminal plates may be spaced around the frame of the switch in accordance with the requirements ofthe particular application for the switch, and the housl and switch housing of our invention, illustrating the device in actual commercial size.

Fig. 2 is a side elevation of the structure of Fig. 1.

Fig. 3 is a fragmentary cross sectional view along the line 3-3 of Fig. 2.`

Fig. 4 is a sectional view of the switch mechanism itself, looking in the direction of the arrows and taken along the line fiof Fig. 3.

Figs. 5A to 5D inclusive, all grouped under Fig. 5, are diagrammatic illustrations of a typical two-lament circuit employing the switch of the present invention.

Fig. 6 is an exploded view illustrating the individual elements in perspective of the complete switch housing shown in Figs. 1 to 3.

Fig. 7 is an enlarged front elevation of' a ter.

minal post for this multi-deck switch, with the illustration showing particularly the construction of the securing rivet or eyelet for assembling the elements of the post.

Fig. 8 is a view partly in section, of a modiiied embodiment of the switch mechanism, with one frame plate removed.

Fig. 9 is a similar view of a further modication of the invention.

Figs. '10A to 10D, all grouped under Fig. 10, show the four operating positions in a typical circuit, utilizing the switch of Fig. 8 for controlling the same.

Fig. 11, including Figs. 11A and 11B, illu'strates the on and off position of a circuitcontrolled by the switch of Fig. 9.

Fig. 12 is an enlarged view of a terminal plate. Each of the superimposed terminal plates are identical.

In the illustrated embodiments of the invention, the switch mechanism includes a pair of insulating frame plates I 0 and II spaced apart and supported on three spacing and terminal posts. These posts are of two diierent types.

^ The post I2 in the structure of Figs. 3 and 4 comprises a metal member I3 with the upper and lower ends of the metal member abutting the inside surfaces of the adjacent frame plates Ill and i I. A stationary contact for each of the two superimposed contact discs, as will be hereinafter described, is secured between the metal spacing and supporting member I3 and metal terminal plates Id and I6 mounted upon the outside of these members. l

For purposes of uniformity over all of the spacing and terminal posts, an apertured insulating plate I'I its overthe metal member I3 to be positioned intermediate the terminal plates I4 and I6, to separate such plates. Electrically, however, the metal member I3 makes the terminal plates I4 and I6, as Awell as their assoaaoaros u ciated stationary spring contacts, common to one another, and the insulating plate I'I has no electrical function. The other two spacing and terminal posts of the switch of Figs. 3 and 4, which posts are designated by the reference character I8, comprise a spacing post or mem; ber I9 abutting the inner surfaces of the plates I@ and I I, in the same manner as metal terminal post I3. Metal terminal plates I@ and I5 are` mounted upon the outside of said-members to secure between the plate and the member a stationary spring contact, as will b e hereinafter described. The' apertured insulating plate IT- separates and insulates'the plates I4 and I6 from one another and the circuits through these terminal plates may be electrically independent of one another, inasmuch as their corresponding stationary spring contacts, and bridging rotors within said contacts are insulated from one another when used in combination with a post I8.

Lugs 2| extending upwardly from the terminal post Ill, and similar lugs 22 extending downwardly from the terminal plate IS in each of the embodiments of the invention, protrude through corresponding apertures 25 in the upper and lower frame plates I @and II, and when upset bind the frame plates onto the spacing or supporting members I3 and I9. The frame plates are further supported and spaced apart at a fourth point by the shouldered extensions on a U-shaped mounting stem 23, having similar lugs 2&3 extending through the frame plates to be upset thereon.

The circuit making and breaking mechanism varies as to each of the three embodiments of the invention. As to the embodiment of Figs. 3 and 4, this includes a pair of superimposed toothed rotors of insulating material indicated by the reference characters 2S and 2l. A fourcontact portion bridging member 26' is secured on the rotor 26, and a two-contact portion bridging contact 2l is mounted on the rotor 27. This rotor construction is apparent from Figs. 3, 4 and 5. The rotors are non-rotatably secured on a spindle 28 journalled in the frame plates I0 and II as shown in Fig. 4, and spaced apart on said spindle by a ratchet wheel 29 non-rotatably mounted thereon, and insulating discs 3| separating the ratchet and rotors. The ratchet wheel 29 is preferably built up from a pluralityin this instance, ilve--of identical metal wheels, which thinner wheels may be punched out and assembled at a lower'I cost than providing a single wheel of the thickness illustrated. Simultaneous rotation of the two rotors and the maximum flexibility of mounting of the switch, so far as the position of said mounting is concerned, is

secured by means of actuating mechanism including a universal lever 32 seated at its inner end on a seat 33 of the mounting stem 23, with' the universal lever operating through a connecting link 3d, to which is secured at the end thereof, a U-shaped actuating pawl 3B, such as is employed in the structure of copending application Serial No. 51,466. One of the legs of the U-shaped pawl engages the teeth of the ratchet wheels 29 for step-by-step rotation of the mechanism.

'I'he rotors rotatably move through, and the bridging members engage, stationary contacts 3l. These stationary contacts include a curved spring contact portion, and a mounting portion 38 integral therewith. The mounting portion of each corresponds in size and shape to a terminal plate I6 or I6, and ts between such plate I4 or 7i I 6 and a corresponding spacing and mounting member I3 or I9 as shown clearly inFig. 4. The mounting portions 38 are apertured at 39 to correspond with apertures in the spacing and mounting members and the terminal plates, and the assembly is completed by a rivet or eyelet 4I having an annular iiange or stop shoulder 42 on the inner end, and a thin walled portion 43 (Fig. 7)- at the outer end, which is split when peened over in the assembly of the posts. The assembly is accomplished by inserting the eyelet 4I in the apertures with the flange 42 bearing against either the post I3 or I9. 'I'he'relatively thin walled portion 43 at the outer end of the eyelet extends through a hexagonal aperture 45 (Fig. 12) in plates I4 or I6, and this portion is peened over or upset by a tool with a shape to correspond to the countersunk aperture to split slightly and spread the wall out over the edge of the aperture as shown particularly in Fig. 7.

In using a tool corresponding to the polygonally shaped countersunk aperture, the metal of the eyelet is upset .in such a form that the eyelet will be prevented from turning in the post. This member' may be used merely as a securing member, as shown at A in Fig. 4, in which case it is not drilled out in the center, or it may be used to carry a terminal screw 44 in an internal thread 46. In the latter case, when a wire has been placed around the terminal screw, against I the split face 43 (this split face is of course the walled portion as heretofore described), as the screw is turned in, pressure is brought to bear on the split face 43 and by virtue of the pulling action of the screw, the face is spread out further and Athe intermediate post, terminal plate and stationary contact members are pulled and clamped more securely together. This action makes possible at all times a rm, clean engagement between the conducting elements. This same result may be accomplished, of course, by merely turning in the screw 44 against the face 43 without an intermediate conductor wire, if

there happens to be no wire connection to that terminal.

As stated above, the particular embodiments of the invention illustrated in Figs. 3, 8 and 9, each have a switch mechanism which is only one and one-half inches in diameter and eleven-sixteenths inches in height, with the actuating end oi the universal lever and its corresponding seat three-eighths inch in diameter. In this small size, which is little more than the size of a singlepole switch for single circuit control, it is possible to have a double-pole switch and accomplish multiple circuit control, and by virtue of the particular actuating mechanism, mount the switch in any desired position for direct or remote control. It is desirable with the present switch to provide a snap cover housing matching the switch mechanism in simplicity and size. 'I'his housing is illustrated in its exact commercial dimensions in Figs. l and 2, and referring more particularly to Fig. 6, includes a metal cup-shaped housing l, an insulating disc 48 to lie at the bottom of the housing, and a split ring-shaped insulating lining 49 to cover the inner wall of said housing. This general type of housing is illustrated in Despard Patent No. 1,538,274, for a switch having only a single terminal screw on a side and consequently only a single wire thereto, as contrasted to a plurality of superimposed terminal screws with a plurality of conductors relatively closely spaced together, as provided in the present invention.

To permit assembly of the wire conductors on the superimposed terminals of the switch mechanismV before assembly of the same in the houslng, and then accomplish separation for insulating purposes between superimposed conductors, without any lost space in the housing, a slit 5I is provided extending vertically from a tapered notch 5I' in the upper edge of the lining 49 to an aperture 52 closed except for the slit 5I which is merely a line cut. This slit and aperture when the lining is placed in the housing 4l, corresponds in position to an elongated opening 53 therein. The conductor is held in the aperture 52 of the insulating lining away from the metal housing and an adjacent conductor 56 by means of the slit 5I closing because of the resiliency of the material of the lining after the insertion of the conductor. It will be noted that the tapered notch 5I' facilitates the entrance of a conductor wire 54 into the line slit 5I, but after the conductor is pushed through the slit to the aperture 52, the portions of the lining adjacent lthe slit snap together and the conductor is practically locked in the then closed aperture 52. In sliding a conductor down through slit 5I, the portions of the relatively stiff insulating lining @il adjacent the slit bend or spring out to open the slit wide enough to permit passage oi the conductor therethrough. The relative width of the opening 53 permits this, as may be seen in Figs. 2 and 3. With the cover for the housing, as will be hereinafter described, in the closed position of Fig. 2, the rim of the cover extends down approximately 1%; inch from the top edge of the lining IIS, and below the tapered notch 5I. This makes it impossible to spring the portions of the lining adjacent the slit outwardly, and with the switch in the housing, they wont spring or bend inwardly, so that it is substantially impossible to open the slit 5I sufficiently to slide the conductor out, and with the round aperture 52 closed, as described above, the conductor is locked in said aperture. y

In the meantime, the mounting stem 23 is inserted in the slot 55 of the housing, while the ends 55' of the lining 49 abut the sides of the stem, as shown in Fig. 3. Open slots 60 and 60 in the lining 49 correspond to similar slots in the housing il and accommodate conductors to other terminals on the switch besides that to which conductor 54 is fastened. In assembling the housing, the disc 48 is initially placed in the bottom of the housing M and the lining 49 is then inserted. After insertion of the switch mechanism, a cover 5l having an insulating disc 58, properly centered therein by means of tabs 59, is pressed into place on the cup-shaped housing and held thereon by detents 6I slipping into corresponding 'apertures 62 in the wall of the housing. After this assembly, the switch may be mounted in a cut-out box, in a motor housing, on a floor lamp, or any other desired place occupying a minimum amount of space, and positioned in any desired manner. The housing illustrated in Figs. 1, 3 and 6 is particularly adapted for the switch of Figs. 3 and 4, with one common terminal post as I2, one bi-terminal active post as I8, and a dead post to which no stationary contacts are connected. It is understood that the housing may be adapted to other switches as illustrated herein, with closely spaced active terminals and consequently closely spaced conductor wires extending to said terminals, andA the slit and aperture construction of the insulating lining may be particularly adapted to locking a conductor wire therein as above described.

A very desirable of Fig. 3 is illustrated in Fig. 5, including Figs. A to 5D, wherein the switch controls a twoiilament lamp as discussed above. Line L1 is connected to terminal screw 44 on the terminal I2, which includes a metal plate I3 making the stationary contacts 31 for each of the rotors 26 and 21 common, electrically,` to one another. In the position illustrated in Fig. 5A, the circuit extends from line L1 through the bridging contact 26, through the low i'llament of the lampV lowfand medium filaments are lighted. The

circuit extends from line L1 to the common terminal I2, through the bridging contacts 26'and 21' on the upperand lower rotors respectively, through both filaments of the lamp. to the line L2. Fig. 5D illustrates the off position for the lamp wherein stationary contacts 31 common to line L1 are both on dead teeth of the rotors 26 and 21 respectively.

As appears from the' diagrammatic illustration of Fig. 5, double length contact portions are provided for the bridging contact 21', which contact portions each extend over two teeth of an eight-toothed rotor 21 identical with the superimposed rotor 26. It is understood, of course, that a six-toothed rotor with two elongated teeth could also be used.

The embodiment of the invention illustrated in Fig. 8 employs the same four-point support for the frame plates previously mentioned, but in this combination the three terminal posts are all the same as that designated by the referencel character I8, and all active, with an insulating spacing and supporting member I9 and independent terminal plates I4 and I6 (this is the lower of the two identical superimposed plates and is not visible in this figure), which secure stationary contacts 31 to the terminal posts by means of rivets or eyelets 4I in the manner heretofore described. Identical insulating rotors 66 having split bridging contacts 66' are superimposed in the manner heretofore described and non-rotatably mounted on the spindle 28. A typical circuit to be controlled byv this switch is illustrated in Fig. l0, wherein `line L1 is` connected to a terminal plate I4 for instance, by means of the terminal screw therein, and line L2 is connected to the lower terminal plate or member I6 in the same manner. The plates are insulatingly separated by an insulating plate as I1 therebetween, as heretofore described. This circuit includes two independent loads E and F which may be motors, lamps, or the like. In the position of the switch as illustrated in Fig. 10A, load E is energized by a circuit extending from line L1 through terminal I4 and its corresponding stationary contact, through one of the split contact bridging members66' on a rotor 66, through a second terminal plate I4, the load E, terminal plate I6 corresponding to the lower or underneath deck (not shown), as viewed in Fig. 8, through bridging contact 66' on the lower rotor adaptation of the switch 66, through a stationary contact and corresponding terminal, and then to line Lz connected to another lower terminal plate, which is designated throughout this specification by reference character I6. Because of the use of split bridging contacts 66', load F in this position is not in contact with either of the line connections.

Fig. 10B illustrates an off position for both loads, while Fig. 10C illustrates a circuit wherein load F is energized. For this circuit position the rotors 66 have been rotated through two posi.- tions from that of Fig. 10A, and the previously dead bridging contacts 66' are now connected across line L1 and line L2 through terminals I4 and I6 on the upper and lower decks, as previously described.

Upon the next step-by-step movement of the rotor, as illustrated in Fig. 10D, the circuit is broken for each of the loads, thus illustrating a second oi position. It is understood that successive rotary operations, for a complete cycle,

are merely repetitions oi the four positions illustrated in Figs. 10A to 10D.

A third embodiment of the invention is illustrated in Fig. 9, and a typical circuit connection therefor is illustrated in Fig. 11. This switch again includes the four-point spacing and suspension for the two frame plates, with active terminal posts I8 on each side and a similar but dead terminal post I8 opposite to the mounting stem 23 in the entire frame. Therotors 68 on the two decks of the switch are identical, and each carries a bridging Contact 68 having four contact vportions on alternate teeth over the eight-toothed insulating rotor. The circuit adaptation for this switch includes merely a single load G connected across an upper terminal plate I4 and a lower terminal plate I6 on a single complete post assembly as I8. OLine L1 is connected to terminal plate I4 oppositely positioned to that to which the load is connected, and the other side of the circuit, line L2 is connected to a terminal plate I6. Fig. 11A illustrates the 1 on or energized position of the load G wherein the circuit extends from line L1 through a bridging contact 68', through the load G to the other bridging contact 68', terminal plate I6, and line L3 connected'thereto. Fig. 11B illustrates the ofi position for the circuit, with the rotors rotated through one step in the rotation, to bring the stationary contact and terminal members in engagement with dead teeth on the rotors.

The disclosures of this application are illustrative, and-the invention is not to be limited by them. In fact, if modifications or improvements are not at once obvious, they may be devised in the course of' time to make additional use iof the broad ideas taught and covered by this application. The claims are intended to point out novel features and not to limit the invention except as ing a cup-shaped metal body portion having aside wall with a slot corresponding in position when the switch is mounted therein, to the plurality of superimposed terminal contacts, and an elongated slot in said side wall spaced laterally from said first'slot, an insulating lining for said body portion having a relatively shallow slot corresponding to the iirst slot in the body portion side wall for supporting one of the superimposed conductors and insulating it from the body portion, and a slit in the lining corresponding to said elongated slot extending to an aperture of such a shape as to itself support and retain therein a second of the superimposed conductors insulated from said body portion and said first conductor, and a cover for said housing.

2. The combination, with electric switching mechanism having an open frame and including a pair of terminals disposed vertically one above the other on the outside of such mechanism and relatively close together, of a housing for such mechanism including a cup-shaped metal body portion having an annular side wall tting relatively closely to said contacts, means for permitting the extension through said body portion of conductors from said two terminals of the switching mechanism including a relatively shallow recess opening from the top edge of the side wall and corresponding in position to the top one of said twolterminals and with a relatively deep recess in said side wall spaced circumferentially from said iirst recess, and an insulating lining for said body portion intermediate 'the contacts and side wall, said lining having a recess corresponding to the shallow side wall recess but smaller than said recess for receiving a conductor from the top one of the pair of vertically disposed terminals to maintain such conductor out of contact with the metal side wall, and `a key hole shaped slot in said lining opening from the top edge thereof and corresponding to the deep side wall recess of such shape as to itself retain therein a conductor from the lower terminal spaced from the metal side wall and the first conductor and permitting easy extension of such conductor from the lower terminal along the open frame of the switching mechanism and into the slot.

3. In combination, an electric switch having a plurality of terminals thereon with at least two of said terminals spaced relatively close together, a housing for said switch including an insulating wall portion, with said wall portion having an opening from one ,edge thereof of such a shape as to itself permit easy insertion therein of a conductor extending from one of said two terminals of the switch to a circuit connection outside the housing but prevent easy withdrawal of said conductor therefrom, and a slot opening from the same edge of the wall portion relatively close to said opening but separated therefrom, of such a shape as to permit easy insertion and easy withdrawal of a conductor extending from the other of said terminals to a connection outside said housing, with said opening and said slot acting to insulatingly separate the two conductors.

4. In combination, a switch mechanism including a terminal member having a conductor wire extending outwardly therefrom, a housing for said switch mechanism including a metal cover, and a rimmed metal cap therefor, an insulating lining for said cover havingan elongated line slit therein extending from a notched opening at the edge of the lining to an aperture in the wall of the lining, with said cover having an opening extending from one edge vertically of the wall thereof corresponding to the notch-slit-aperture portion of the lining but wider and longer than said portion, with the aperture adapted to carry the conductor wire therein out oi' engagement with the metal of the cover and metal of the cap and the lining at the slit closing after insertion of the conductor in the aperture, with the rim of said cap extending down beyond said edge of said lining having the notch therein and acting to prevent a yielding of the lining at the slit to lock said conductor in said aperture.

5. A housing for an electric switch mechanism having a conductor thereon for extending through the housing to a connection outside said housing, said housing including an insulating wall portion having a conductor retaining aperture therein, an elongated opening extending from one edge of said wall portion to said aperture which is narrower than the conductor to be retained in the aperture, with the wall portion on each side of said elongated opening being yieldable sufliciently to permit the enlarging of said opening and the insertion of said conductor through said opening to said aperture, and a cover for said housing having a rim thereon ex-i tending over said wall portion and said elongated opening a suilicient distance and in such a manner as to substantially prevent yielding of the wall portions at said opening to prevent enlarging of said opening for removal of said conductor and to thereby cooperate with said aperture in retaining the conductor-therein.

6. A housing for an electric switch mechanism having at least two conductors thereon for extending through the housing to connections outside said housing and adapted to prevent withdrawal of said conductors from said housing except in a direction substantially at right'angles to one wall thereof and to space one conductor from the other, said housing including an insulating wall portion having a conductor retaining aperture therein, an opening extending from one edge of said wall portion to said aperture which is narrower than the conductor to be retained in the aperture, with thc wall portion on each side of said opening being yieldable suiciently to permit the enlarging of said opening and the insertion of a conductor through said opening to said aperture, a slot extending from said one edge of said wall portion and spaced laterally in said wall portion from said opening being substantially as 4wide as a conductor to be inserted therein for easy insertion and withdrawal of the conductor through said slot, and a cover for said housing extending over said wall portion and said opening and slot a sufficient distance and in such a manner as to substantially prevent yielding of the wall portionsat said opening to prevent the enlarging of said opening to prevent the removal of the conductor through said opening and to thereby cooperate with said aperture in retaining the conductor therein, and extending over said slot a sufficient distance to close said slot and prevent the Withdrawal along said slot of the conductor therein.

RUDOLF POPP.

MARVIN C. CARLSON. 

